Temperature Field Analysis and Experimental Verification of Mining High-Power Explosion-Proof Integrated Variable-Frequency Permanent Magnet Motor

An efficient cooling configuration is critical for ensuring the safe operation of electrical machines and is key for optimizing the iterative design of motors. To improve the heat dissipation performance of high-power, explosion-proof, integrated variable-frequency permanent magnet motors used in mining and reduce the risk of permanent magnet demagnetization, this study considers a 1600 kW mining explosion-proof variable-frequency permanent magnet motor as its research object. Based on the zigzag-type water channel structure of the frame, a novel rotor-cooling scheme integrating axial–radial ventilation structures and axial flow fans was proposed. The temperature field of the motor was simulated and analyzed using a fluid–thermal coupling method. Under rated operating conditions, the flow characteristics of the frame water channel and the temperature distribution law inside the motor were compared when the water supply flow rates were 5.4, 4.8, 4.2, 3.6, 3, 2.4, and 1.8 m3/h, respectively, and the relationship between the motor temperature rise and the variation in water flow rate was revealed. A production prototype was developed, and temperature rise tests were conducted for verification. The test results were in good agreement with the simulation calculation results, thereby confirming the accuracy of the simulation calculation method. The results provide an important reference for enterprises in the design optimization and upgrading of high-power explosion-proof integrated variable-frequency permanent-magnet motors.